Removal of the Outboard Double-Slotted Flap

TASK 27-54-62-000-002-A
Removal of the Outboard Double-Slotted Flap

WARNING: PUT THE SAFETY DEVICES AND THE WARNING NOTICES IN POSITION BEFORE YOU START A TASK ON OR NEAR:

THE FLIGHT CONTROLS
THE FLIGHT CONTROL SURFACES
THE LANDING GEAR AND THE RELATED DOORS
COMPONENTS THAT MOVE.

MOVEMENT OF COMPONENTS CAN KILL OR CAUSE INJURY TO PERSONS AND/OR CAN CAUSE DAMAGE TO THE EQUIPMENT.

WARNING: MAKE SURE THAT THE GROUND SAFETY-LOCKS ARE IN POSITION ON THE LANDING GEAR. THIS WILL PREVENT UNWANTED MOVEMENT OF THE LANDING GEAR, AND THUS POSSIBLE INJURY TO PERSONS AND DAMAGE TO THE AIRCRAFT AND/OR EQUIPMENT.

CAUTION: BE CAREFUL WHEN YOU DO MAINTENANCE TASKS ON THE WING TRAILING EDGE:

DO NOT CAUSE DAMAGE TO THE ELECTRICAL CABLE RACEWAYS.
DO NOT CAUSE DAMAGE TO THE ELECTRICAL CABLE INSTALLATIONS.
MAKE SURE THAT THE ELECTRICAL CABLES ARE INSTALLED CORRECTLY. INCORRECT INSTALLATION CAN CAUSE DAMAGE.

ZONE: 500
ZONE: 600

1. Reason for the Job
Self Explanatory
2. Job Set-up Information
A. Fixtures, Tools, Test and Support Equipment

REFERENCE	QTY	DESIGNATION
No specific	AR	ACCESS PLATFORM 3M (10 FT)
No specific	AR	COVER - PROTECTION
No specific	AR	SAFETY BARRIER(S)
No specific	AR	SUPPORT STRUCTURE - FLAP
No specific	AR	TAPE - ADHESIVE
No specific	AR	WARNING NOTICE(S)
No specific	AR	WRENCH - PNEUMATIC
98D27504083000	1	EXTRACTOR - PIN TRACKS 2 AND 3
98D27504084000	1	EXTRACTOR - PIN, TRACK 4
98D27504115000	2	GAUGES-DISTANCE
98D27604000000	4	COLLAR-SAFETY, SPOILER
98D27604004000	4	COLLAR SAFETY SPOILER
98D27804001000	1	ADAPTOR-DRIVE, SLAT (AND FLAP)

B. Work Zones and Access Panels

ZONE/ACCESS	ZONE DESCRIPTION
500	LEFT WING
600	RIGHT WING
573CB, 575AB, 575BB, 673CB, 675AB, 675BB

C. Referenced Information

REFERENCE	DESIGNATION
TASK 27-50-00-000-002-A	Removal of the Inboard and Outboard Flap Hoisting-Sling
TASK 27-50-00-400-002-A	Installation of the Inboard and Outboard Flap Hoisting-Sling
TASK 27-50-00-866-009-A	Retraction of the Flaps on the Ground
TASK 27-50-00-866-009-A-01	Retraction of the Flaps/Slats on the Ground
TASK 27-51-00-820-004-A	Adjustment of the Forward Eccentrics (Tracks 3 and 4)
TASK 27-54-41-000-001-A	Removal of the Right Angle Gearbox
TASK 27-54-61-000-002-A	Removal of the Flap Kink-Seals and Cushion-Seals
TASK 27-60-00-866-002-A	Extension-Retraction of the Spoilers for Maintenance
TASK 57-55-11-010-002-A	To Lower the Flap Track No. 3 & No. 4 Movable Fairings for Access
Interconnecting Strut - Location and Detail
Details of the Z-Coupling
Details of the Tab Drive Control-Rod (Track 3)
Details of the Tab Drive Control-Rod (Track 4)
Distance Gages - Location and Detail
Outboard Flap Forward-Eccentrics - Location and Detail
Flap to Rotary Actuator Drive-Levers ** ON A/C NOT FOR ALL
Flap to Rotary Actuator Drive-Levers ** ON A/C NOT FOR ALL
Flap to Flap Carriage Connection
Flap Removal and Installation Tools

3. Job Set-up
Subtask 27-54-62-941-056-A ** ON A/C NOT FOR ALL

A. Safety Precautions
(1) As necessary, use the applicable SAFETY BARRIERS, specified by the operator's instructions and your local regulations.
(2) Put a WARNING NOTICE(S) on panel 400VU to tell persons not to operate the landing gear.
(3) Put a WARNING NOTICE(S) on panel 114VU to tell persons not to operate the flight controls.

Subtask 27-54-62-860-056-A ** ON A/C NOT FOR ALL

B. Aircraft Maintenance Configuration

WARNING: MAKE SURE THAT THE TRAVEL RANGES OF THE FLIGHT CONTROLS SURFACES ARE CLEAR. MOVEMENT OF FLIGHT CONTROLS CAN CAUSE INJURY TO PERSONS AND/OR DAMAGE TO EQUIPMENT.

(1) Make sure that the flaps are in the fully retracted position (Ref. AMM TASK 27-50-00-866-009).
(2) Make sure that the 98D27803000000 LOCKING TOOL-FLAP SLAT LEVER,INT. POSITION is on the slat/flap control lever.

Subtask 27-54-62-865-054-A ** ON A/C NOT FOR ALL

C. Make sure that this(these) circuit breaker(s) is(are) open, safetied and tagged:

PANEL	DESIGNATION	FIN	LOCATION
** ON A/C NOT FOR ALL
49VU	FLIGHT CONTROLS/FLP/CTL AND MONG/SYS1	6CV	B07
** ON A/C NOT FOR ALL
49VU	FLIGHT CONTROLS/FLP/CTL AND MONG/SYS1	6CV	B02
** ON A/C NOT FOR ALL
121VU	FLIGHT CONTROLS/FLP/CTL AND/MONG/SYS2	8CV	Q21

Subtask 27-54-62-010-052-A ** ON A/C NOT FOR ALL

D. Get Access
(1) Put the ACCESS PLATFORM 3M (10 FT) in position below the applicable outboard flap.
(2) Remove the access panels for the applicable wing:

Interconnecting Strut - Location and Detail ** ON A/C NOT FOR ALL

for the left wing, remove 573CB 575AB 575BB
for the right wing, remove 673CB 675AB 675BB.

(3) Lower the flap track No. 3 and No. 4 movable fairings (Ref. AMM TASK 57-55-11-010-002).
(4) Disconnect the applicable torque shaft from the right angle gearbox (Ref. AMM TASK 27-54-41-000-001).
(5) Install the 98D27804001000 ADAPTOR-DRIVE, SLAT (AND FLAP) on the right angle gearbox.
(6) Use a WRENCH - PNEUMATIC to turn the 98D27804001000 ADAPTOR-DRIVE, SLAT (AND FLAP) to extend the flaps to position 1.
(7) Remove the flap kink seals (Ref. AMM TASK 27-54-61-000-002).
(8) Use the pneumatic wrench and the 98D27804001000 ADAPTOR-DRIVE, SLAT (AND FLAP) to fully retract the flaps.

Subtask 27-54-62-020-060-A ** ON A/C NOT FOR ALL

E. Preparation for Removal
(1) Disconnect the interconnecting strut (1):

Interconnecting Strut - Location and Detail ** ON A/C NOT FOR ALL

(a) Remove and discard the cotter pin (2).
(b) Remove the nut (3), the washer (4) and the bolt (6).
(c) Hold the interconnecting strut (1) to the inboard flap with adhesive tape.
(2) Disconnect the Z-coupling:

Details of the Z-Coupling ** ON A/C NOT FOR ALL

(a) Use the pneumatic wrench and the 98D27804001000 ADAPTOR-DRIVE, SLAT (AND FLAP) to extend the flaps to position 1.
(b) Remove and discard the cotter pin (24).
(c) Remove the nut (25) and the washer (26).
(d) Use the pneumatic wrench and the 98D27804001000 ADAPTOR-DRIVE, SLAT (AND FLAP) to retract the flap to the 0 position.
(e) Remove and discard the cotter pin (18).
(f) Remove the nut (19), the washer (20) and the spacer(s) (21).
(g) Remove the bolt (22).
(h) Remove the lever (27) and the remaining spacer(s) (21).
(i) Temporarily install the spacer(s) (21), the washer (20) and the nut (19) on the lever (27).
(j) Temporarily install the lever (27) on the attachment bracket (23) with the bolt (22), the washer (26) and the nut (25). Turn the lever (27) forward as far as possible and hold it in this position with TAPE - ADHESIVE.
(k) Turn the lever (17) forward as far as possible and hold it in this position with adhesive tape.
(3) Use the pneumatic wrench and the 98D27804001000 ADAPTOR-DRIVE, SLAT (AND FLAP) to fully extend the flaps.
(4) Make sure that the 98D27803000000 LOCKING TOOL-FLAP SLAT LEVER,INT. POSITION is on the slat/flap control lever.
(5) Disconnect the tab drive control-rod (50) from the track 3 carriage (38):

Details of the Tab Drive Control-Rod (Track 3) ** ON A/C NOT FOR ALL

(a) Remove and discard the cotter pin (41).
(b) Remove the nut (42), the washer (40), the bolt (52) and the loose bush (39).
(6) Disconnect the tab drive control-rod (73) from the track 4 carriage (63):

Details of the Tab Drive Control-Rod (Track 4) ** ON A/C NOT FOR ALL

(a) Remove and discard the cotter pin (78).
(b) Remove the nut (77) and the washer (76).
(c) Remove the hinge pin (65) sufficiently to let you remove the tab drive control-rod (73). Do not fully remove the hinge pin (65).

NOTE: If you fully remove the hinge pin (65) from the carriage (63), the roller bearing block (64) will fall out of alignment.

(7) Install the distance gages:

Distance Gages - Location and Detail ** ON A/C NOT FOR ALL

CAUTION: MAKE SURE THAT THE DISCONNECTED PARTS DO NOT TOUCH AND/OR CATCH THE ADJACENT STRUCTURE WHEN YOU MOVE THE FLAP. THIS WILL PREVENT DAMAGE TO THE WING.

(a) Manually push the tab forward and install the 98D27504115000 GAUGES-DISTANCE (86) and (89) at the track 3 and the track 4 positions.
(b) At the track 3 position, put a distance gage (86) in position each side of the track and install the pins (87) and (88).
(c) At the track 4 position, put the distance gage (89) in position and install the pin (90).
(8) Check the value on the label (101) attached to the outboard side of the flap track 3 beam assembly:

Outboard Flap Forward-Eccentrics - Location and Detail ** ON A/C NOT FOR ALL

(a) If the value on the label (101) is '0', do not adjust the forward eccentrics.

NOTE: At the '0' position, the punch marks (108) on the forward eccentrics will be aligned to the zero datum position.

(9) If the value on the label (101) is not '0', adjust the forward eccentrics to the zero datum position (Ref. AMM TASK 27-51-00-820-004).

Subtask 27-54-62-480-051-A ** ON A/C NOT FOR ALL

F. Installation of the Hoisting Sling

CAUTION: OPERATE THE HOIST SLOWLY, WHEN YOU PUT THE SLING IN TENSION. DO NOT TRY TO REMOVE THE FLAP BECAUSE THIS WILL CAUSE DAMAGE.

(1) Install the hoisting sling (Ref. AMM TASK 27-50-00-400-002).
(2) Use the hoist to carefully lift the hoisting sling until it holds the weight of the outboard flap.

Subtask 27-54-62-860-055-A ** ON A/C NOT FOR ALL

G. Aircraft Maintenance Configuration
(1) Fully extend the applicable spoilers 2, 3, 4 and 5 (Ref. AMM TASK 27-60-00-866-002).
(2) Put a 98D27604000000 COLLAR-SAFETY, SPOILER or 98D27604004000 COLLAR SAFETY SPOILER on the piston rod of each servo-control.

4. Procedure

CAUTION: BE CAREFUL WHEN YOU DO MAINTENANCE TASKS ON THE WING TRAILING EDGE:

DO NOT CAUSE DAMAGE TO THE ELECTRICAL CABLE RACEWAYS.
DO NOT CAUSE DAMAGE TO THE ELECTRICAL CABLE INSTALLATIONS.
MAKE SURE THAT THE ELECTRICAL CABLES ARE INSTALLED CORRECTLY. INCORRECT INSTALLATION CAN CAUSE DAMAGE.

Subtask 27-54-62-020-053-B ** ON A/C NOT FOR ALL

WARNING: USE PROTECTIVE GOGGLES AND GLOVES WHEN YOU REMOVE OR INSTALL LOCKWIRE. EACH TIME YOU CUT LOCKWIRE, REMOVE AND DISCARD IT IMMEDIATELY. LOOSE LOCKWIRE CAN CUT YOU OR MAKE YOU BLIND, AND/OR CAN CAUSE DAMAGE.

A. Removal of the Outboard Double-Slotted Flap

Flap to Rotary Actuator Drive-Levers ** ON A/C NOT FOR ALL

Flap to Flap Carriage Connection ** ON A/C NOT FOR ALL

CAUTION: SUPPORT THE FLAP ALONG THE FULL LENGTH OF THE TRAILING EDGE. THIS WILL PREVENT DAMAGE TO THE FLAP.

(1) Disconnect the flap drive arms (124) from the rotary actuator drive-levers (128) at the track 3 and the track 4 positions:

NOTE: The weight of the outboard flap is 205 kg (452 lb).

(a) Remove the nut (122), the bolt (119), the washer (120) and disconnect the bonding strap (121).
(b) Remove and discard the cotter pins (127).
(c) Remove the nuts (126), the washers (125) and the bolts (123).
(d) Carefully let the outboard flap move aft until the flap carriages touch the end stops (149).
(2) Disconnect the outboard flap from the flap track 3 carriage and the flap track 4 carriage:
(a) Remove and discard the lockwire from the bolts (148).
(b) Remove the bolts (148) and disconnect the bonding straps (147).
(c) Remove and discard the cotter pins (144).
(d) Remove the nuts (143).
(e) Remove and discard the crushable washers (142).
(f) Remove the nuts (145), the washers (146) and the locking plates (141).
(g) Remove and discard the lockwire from the nuts (152).
(h) Loosen the nuts (152) sufficiently to let the failsafe hook assembly (153) move.
(i) Install the 98D27504083000 EXTRACTOR - PIN TRACKS 2 AND 3 and the 98D27504084000 EXTRACTOR - PIN, TRACK 4 to the carriage bolts (150).

Flap Removal and Installation Tools ** ON A/C NOT FOR ALL

NOTE: Make sure that you screw the extractor tools fully on to the threads.

(j) Remove the carriage bolts (150). If necessary, carefully lift the flap with the hoist and sling sufficiently to release the weight off the bolts (150).
(k) Remove the splined bushes (140).
(3) Remove the flap from the wing:

CAUTION: MAKE SURE THAT THE FLAP DOES NOT HIT THE AIRCRAFT STRUCTURE.

CAUTION: MAKE SURE THAT THE SUPPORT STRUCTURE IS CLEAN AND DOES NOT HAVE ANY SHARP POINTS.

(a) Carefully and slowly lift the outboard flap off the flap track carriages.
(b) Move the outboard flap with the hoist and lower it onto the SUPPORT STRUCTURE - FLAP.
(4) Put COVER - PROTECTION, where necessary, over the disconnected items of the flap.

Subtask 27-54-62-080-051-A ** ON A/C NOT FOR ALL

B. Removal of Equipment
(1) If necessary, remove:

the hoisting sling from the outboard flap (Ref. AMM TASK 27-50-00-000-002)
the 98D27804001000 ADAPTOR-DRIVE, SLAT (AND FLAP) from the right angle gearbox
the 98D27504083000 EXTRACTOR - PIN TRACKS 2 AND 3 and 98D27504084000 EXTRACTOR - PIN, TRACK 4 from the carriage bolts (150).
Flap Removal and Installation Tools ** ON A/C NOT FOR ALL

[Rev.10 from 2021] 2026.04.01 06:58:03 UTC